Fill-Trol System Instruction Manual

1400 Division Road, West Warwick, RI 02893 T: 401.884.6300 F: 401.885.2567 www.amtrol.com
The FILL-TROL
®
Unit
INSTALLATION, OPERATION & SERVICE INSTRUCTIONS
For Use with Fill-Trol Combination
Expansion Tank and Valve Units
Part #: 9015-026 (01/11)
READ CAREFULLY THE PRODUCT
INSTALLATION, OPERATING AND
MAINTENANCE MANUAL. FAILURE TO
FOLLOW THE INSTRUCTIONS AND WARNINGS IN THE MANUAL MAY
RESULT IN SERIOUS OR FATAL INJURY AND/OR PROPERTY DAMAGE,
AND WILL VOID THE PRODUCT WARRANTY. THIS PRODUCT MUST BE
INSTALLED BY A QUALIFIED PROFESSIONAL. FOLLOW ALL APPLICABLE
LOCAL AND STATE CODES AND REGULATIONS, IN THE ABSENCE OF
SUCH CODES, FOLLOW THE CURRENT EDITIONS OF THE NATIONAL
PLUMBING CODE AND NATIONAL ELECTRICAL CODE AS APPLICABLE.
WARNING: Mount vertically only. Do not mount on
dead-end pipe.
THIS IS THE SAFETY ALERT SYMBOL. IT IS USED TO ALERT
YOU TO POTENTIAL PERSONAL INJURY AND OTHER
HAZARDS. OBEY ALL SAFETY MESSAGES THAT FOLLOW
THIS SYMBOL TO REDUCE THE RISK OF PERSONAL INJURY
AS WELL AS PROPERTY DAMAGE.
This product, like most products under pressure
may, over time, corrode, weaken and burst or
explode, causing serious or fatal injury, leaking or
flooding and/or property damage. To minimize risk, a licensed professional
must install and periodically inspect and service the product. A drip pan
connected to an adequate drain must be installed if leaking or flooding could
cause property damage. Do not locate in an area where leaking could cause
property damage.
EXPLOSION OR RUPTURE HAZARD. relief valve must be installed to prevent
pressure in excess of local code requirement or maximum working pressure
designated in the Product Manual, whichever is less. Do not expose product to
freezing temperatures or temperatures in excess of those set forth in manual.
Failure to properly size the product, or follow instructions in the manual, may
result in excessive strain on the system and may lead to product failure,
leakage, flooding and/or property damage.
DANGER! EXPLOSION HAZARD. Do not adjust
the pre-charge or re-pressurize this product
except for any adjustments at the time of the
initial installation. If you attempt to adjust the pre-charge pressure or add
pressure to a product that is corroded, damaged or with diminished integrity, the
product can burst or explode, causing serious or fatal injury and/or
property damage.
NOTE: Inspect for shipping damage and notify freight carrier or store where
purchased immediately if damage is present. Avoid risk of personnal injury
or property damge. If the product appears to be malfunctioning or shows
signs of corrosion, call a qualified professional. Current copies of the product
manual can be viewed at www.amtrol.com. Use proper safety equipment when
installing. You must comply with all plumbing codes.
FAILURE TO PROPERLY SEAL WILL RESULT
IN LOSS OF PRECHARGE CAUSING
PRODUCT TO FAIL.
POTABLE WATER WARNING. This product
must not be used in potable water systems or
open systems of any kind. These plumbing
systems contain oxygenated water, which will cause internal corrosion and
premature tank failure. Use a Therm-X-Trol
®
for open system
expansion control.
The FILL-TROL
®
unit is a combination TANK (the unique, specially adapted,
pressurized, EXTROL
®
diaphragm-type expansion tank), and a specially-
designed automatic pressure reducing valve.
The FILL-TROL tank provides an air chamber to receive the expanded volume
of water, which is created in the heating system as the water is heated. It is,
therefore, essentially an expansion tank. Pressurizing the tank with a 12 PSIG
air charge results in the pressure reducing valve being set to 12 PSIG. Any
adjustment to the precharge automatically adjusts the pressure reducing valve
setting. It is air-charged at the factory to 12 PSIG and is ready to install in
residential and most commercial systems without adjustments when received
provided the system is set for 12 PSIG.
The FILL-TROL valve fills the system with water and automatically shuts off the
flow when the system is filled and pressurized to 12 PSIG. It will also restore the
system pressure to 12 PSIG if the pressure falls below this point.
The FILL-TROL unit, therefore, will automatically take care of system water
expansion and automatically fill the system and maintain a minimum system
pressure in a simple manner to provide a more satisfactory heating system
operation. This product must be installed by a qualified professional.
MARK OF THE ORIGINATOR
INSTALLATION
An ideal residential FILL-TROL installation is to mount it on the bottom of an
AMTROL air vent and purger, located on the heating system supply main or it
may be in a standard pipe tee (Fig. 1).
TO INSTALL
1. Make connection to system with 1/2” pipe nipple from tapping
marked “SYSTEM”.
2. Connect 1/2” copper tubing cold water supply to 1/2” compression fitting
connection at “SUPPLY”.
OPERATION
The FILL-TROL unit operates in the following manner:
Water enters the FILL-TROL valve through the 1/2” compression fitting
connection, passes through the strainer and pushes open the spring-loaded
check valve. It then flows through the automatic shut-off valve, which is held
in the open position by the charge pressure in the FILL-TROL tank forcing
the diaphragm against the pressure plate, which raises the fillgate stem,
compressing the automatic shut-off valve spring. The water then flows through
the valve body and through the system connection to the heating system. As
the system reaches fill pressure of 12 PSIG, the diaphragm in the FILL-TROL
tank depresses, permitting the automatic shut-off valve to close.
If the system falls below 12 PSIG, the diaphragm again pushes open the
automatic shut-off valve, permitting water to flow into the system to restore
system pressure.
NOTE: Although FILL-TROL is shipped from the factory with a standard 12
PSIG air charge which automatically sets the minimum fill pressure to 12
PSIG, other minimum fill pressures may be selected by simply increasing or
decreasing the air charge in the tank to the desired minimum fill pressure.
FILL-TROL must be empty (free of water) when changing the air charge.
To place FILL-TROL unit into operation, proceed as follows:
A. Open water supply shut-off valve and allow system to fill.
B. After system is filled, the pressure should be 12 PSIG. After the boiler is
brought up to operating temperature, pressure gauge will read higher than
fill pressure. If the pressure is higher than desired, draw water from system
until desired gauge reading is obtained. A good operating pressure is 18-25
PSIG. Do not let air out of the FILL-TROL tank.
MAINTENANCE
To remove screen in FILL-TROL valve for cleaning, shut off main water supply
to heating system and remove compression nut.
A heating system professional should check the complete heating system
yearly and more frequently as the system ages.
FIG. 1